EuP & Electric Motor legislation. Chris Lawton CSO

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2 EuP & Electric Motor legislation Chris Lawton CSO

3 Outline Concern is carbon, not energy However, energy efficiency is important because: It reduces the electricity that has to be generated and associated carbon It reduces the amount of generating plant that has to be built, and paid for Everything suggests that energy prices will continue to rise Over the long term, as electricity is de-carbonised, regulatory pressure will reduce, but customer demand will increase

4 Electrical Power Generation!

5 UK Industrial Electricity Usage 65% motors

6 Motor Efficiency % Previous European efficiency bands pole 2 pole Motor Output kw

7 Previous Efficiency Levels Efficiency Class EFF1 (Voluntary Agreement for the Manufactures acc. with CEMEP) power η 2-pole η 4-pole In kw Motors Motors 1,1 82,8 83,8 1,5 84,1 85,0 2,2 85,6 86,4 3,0 86,7 87,4 4,0 87,6 88,3 5,5 88,6 89,2 7,5 89,5 90,1 11,0 90,5 91,0 15,0 91,3 91,8 18,0 91,8 92,2 22,0 92,2 92,6 30,0 92,9 93,2 37,0 93,3 93,6 45,0 93,7 93,9 55,0 94,0 94,2 75,0 94,6 94,7

8 OUTLINE The Voluntary Agreement, since 1998, of CEMEP for motor manufactures has run out ( classes EFF3 /EFF2/EFF1) from June 15 th New Efficiency standards for Electric motors, is now a mandatory regulation in Europe ( Eup lot 11 ). Base of the regulation is the new international IEC standard, introduced during It defines the following efficiency classes for Electric motors : IE1 = Standard Efficiency (comparable to previous EFF2) IE2 = High Efficiency (comparable to previous EFF1 and USA EPACT) IE3 = Premium Efficiency (comparable to USA NEMA Premium Dec 16th 2010 ) IE4 = Super Premium Efficiency. IEC uses the efficiency levels set in the MEPS Guide 1 st Edition February (MEPS: Minimum Efficiency Performance Standard).

9 Efficiency levels in Europe Efficiencies OLD version Comparison Efficiencies NEW version EFF3 Low efficiency - - EFF2 Standard efficiency IE 1 Standard efficiency EFF1 High efficiency IE 2 High efficiency - IE 3 Premium efficiency - IE 4 Super premium efficiency

10 New European Efficiency Levels IEC Efficiency Classes in acc. with IEC

11 New Efficiency levels in Europe & time line EUROPE (EuP) As from 16 June 2011, minimum energy efficiency requirement to be at IE2 level for all motors covered 2,4,6pole, 0.75 to 375 kw; ( Entered onto the market for the 1st time from Manufacture) From 1 January 2015, minimum energy efficiency requirement to be at IE3 level for 7,5-375 kw motors alone, or together with a IE2 level for 7,5-375 kw motor when equipped with an appropriate VS drive; From 1 January 2017, minimum energy efficiency requirement to be at IE3 level for 0, kw motors alone, or together with a IE2 level for 0, kw motor when equiped with an appropriate VS drive.

12 So what is effected?

13 Saving potential in electric motordriven systems Motors with fixed speed Increased use of energy saving motors 4,0 M t CO 2 Per ann 10% Motors with electronic speed control Electronic speed control 12,0 M t CO 2 Per ann 30% Mechanical system optimization Mechanical system optimization 24,0 M t CO 2 Per ann 60% Source: ZVEI

14 Seriously Consider Running v Capital Cost Capital Running 10 Year Costs Capital 1% Running 99%

15 how long does it take for electricity cost = motor purchase cost?

16 electricity cost = motor purchase cost in less than one month!

17 life-time cost

18 Consider the life time Costs Input Kw = Kw efficiency = hours x Input kw x unit cost

19 Example 75kw, 4 pole High efficiency W-DF250M 24/7 operation at full load 10 years Efficiency 94.7% Cost 9 p/kwh Running Cost 624,393

20 Cost of not changing Old 75kw, 4 pole motor, ( or rewound several times ) At only 3% less efficient than an IE2 motor Extra running costs over 10 years Equivalent to 4 new 75kw W IE2 motors

21 Characteristics of high efficiency motors 96 Typical data for 45kW, 4 pole motor 94 High efficiency 92 5% 3% Standard motor /4 load 1/2 load 3/4 load full load 11/4 load

22 Adopting Energy Saving Practices.

23 LOOK AT THE WHOLE SYSTEM. Is the system doing a useful job? Reduce the system losses Improve the power quality Select the driven machinery for best efficiency Switch it off? Slow it Down? Select the motor for best efficiency & Size Reduce transmission losses

24 Motor Management All new motors to be high efficiency motors ( IE2 or IE3 ) Make the repair/replace decision based on lifetime costs before the breakdown Consider replacing working motors with high efficiency motors Use variable speed wherever possible Watch for unnecessary over-sizing

25 Economics of Replacement vs. Repair Depends on many factors... Running hours Load Cost of electricity Cost of new motor Cost of motor repair

26 HEM Management Replace Repair kw rating

27 The next steps Decide to save energy and take action! Engage approved service provider. Identify problem areas. Engage Site Survey / Audits. (Logging & Tagging Motors) Complete repair analysis of on site motors. Energy surveys. And

28 Save Energy with VSDs Look for:... Centrifugal fans and pumps Look to exclude all process dampers & valves

29 Input Power (%) Cube Law 20% reduction in speed = 50% saving in energy Speed (%)

30 References

31 References

32 References

33 SUMMARY Take a systems approach. Use HEM s where ever possible. Implement a high efficient motor management policy. Consider life time costs. Use VSDs to maximise total energy saving. Brook Crompton are perfectly placed to advise on your requirements for motors & VSD packages.

34 Thank you.